Method of producing textile product

ABSTRACT

Forming a textured textile product from a continuous web of randomly interwoven textile fibers wherein the web is passed into a needleloom where a lifting air pressure or vacuum creates a pressure differential across the web raising the web prior to needling. While thus suspended, the web is simultaneously needled together or through a scrim, if employed, with a prearranged needle pattern to produce a high-low or corduroy effect in the web.

United States Patent 1191 Lauman et al.

[451 July 15, 1975 METHOD OF PRODUCING TEXTILE PRODUCT [76] Inventors: Arthur B. E. Lauman; John Edward Bentley, both of Environs Lane. P. O. Box 1974. Dalton, Ga. 30720 22 Filed: Nov. 6, 1973 21 Appl. No.: 413,309

[52] US. Cl. 28/72.2 R; 28/722 R [51] Int. Cl. D04H 18/00 [58] Field of Search 28/4 R, 72.2 R, 72.2 F

[56] References Cited UNITED STATES PATENTS 3,431,611 3/1969 Rentz 28/722 R 3.613.190 10/1971 Crosby 28/4'R 3/1972 Scholtis 28/4 R 1/1973 Summers 28/722 F Primary Examiner-Louis K. Rimrodt Attorney, Agent. or Firm-William E. Mouzavires [5 7] ABSTRACT Forming a textured textile product from a continuous web of randomly interwoven textile fibers wherein the web is passed into a needleloom where a lifting air pressure or vacuum creates a pressure differential across the web raising the web prior to needling. While thus suspended, the web is simultaneously needled together or through a scrim, if employed, with a prearranged needle pattern to produce a high-low or corduroy effect in the web.

15 Claims, 4 Drawing Figures METHOD OF PRODUCING TEXTILE PRODUCT BACKGROUND OF THE INVENTION This invention relates generally to textured textile products, and more particularly to textured textile products formed from a continuous web of interwoven textile fibers. I

Machines for making needled punched fabrics are well known. The needle punched fabric may be formed by needling together a continuous web of random textile fibers or by needling a web of random fibers onto a support backing known as a scrim. Various modifications of this basic combination are also known. For example, several layers of an alternating web and scrim may be needled together when a necessary product thickness is desired. Also, the'tufts of textile fibers which form on the under side of a scrim when a web is needled through the scrim may be cut and formed into a pile-like arrangement.

Different means have been employed to give a textured surface to a needle-punched textile product. For example, the continuous web of textile fibers may be made in varying thicknesses and then needled together to give a high-low effect. In addition, needling of the web can be effected to produce a desired pattern in the resulting product, as evidenced by US. Pat. No. 2,036,766.

Other means for interlacing fibers used in forming nonwoven textile fabrics have also been employed in the art. For example, US. Pat. No. 3,353,225 employs a plurality of air jets in place of needles to interlace fibers. In addition, many different needle arrangements have been previously employed.

When using the above-mentioned methods and de vices, in many instances it is very difficult to produce a sharply defined pattern in the resulting textile product without further sewing, or cutting, or further processing of the needled web.

SUMMARY AND OBJECTS OF THE INVENTION It is therefore an object of the present invention to provide a novel method and apparatus for producing a desired high-low or corduroy configuration in a textured textile product composed of a web of interwoven fibers. Included herewith is the provision ofa novel textured textile product having a desired high-low or corduroy configuration or the like.

A further object is to provide such a method and apparatus which may be used in connection with a conventional or standard commercial needleloom with little or no modification and without sacrificing performance or efficiency of the needleloom.

Another object is to provide such a method and apparatus which may be employed to produce various high-low or corduroy designs as desired.

In practicing the invention in one specific form. the web is formed in a conventional manner in a card and lapper, or similar device, and then placed on a conventional apron and drafted through two draft rollers prior to being introduced into a needleloom. Upon entering the needleloom. the web is lifted by air pressure or vacuum means just prior to needling. The web is raised slightly by this operation, and then needled together with needles arranged in a predeterminedconfiguration. The resulting product has a high-low or corduroy effect.

In a preferred embodiment of this invention, the lifting air pressure is applied to the web through holes in the bedplate of the needleloom. In a second embodiment of the invention, the lifting air pressure is applied to the web just prior to the bedplate of the needleloom. In a third embodiment of the invention, a vacuum means is disposed above the web to lift the same. Additionally, throughout the invention a scrim material can be used as a carrier or substrate to assist in the interlacingof the textile fibers, and provide a backing for the web.

As used herein, the term web includes any batt or sheet of loose fibers, arranged randomly or in alignment. The term fiber includes both natural and synthetic fibers, of any necessary weight, length or mixture to produce the desired textile product.

DRAWINGS The above and other objects and advantages of the invention will become apparent from the following detailed description, taken in connection with the accompanying drawings, in which drawings:

FIG. 1 is a perspective view of a fragment of the resulting textured textile product of the present invention.

FIG. 2 is an elevational view of the apparatus em ployed in the present invention with parts of a needleloom shown in cross-sections,

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2, with certain portions removed,

FIG. 4 is an enlarged view of the textile product as it leaves the needleloom of FIG. 2.

DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION The textured textile product of the present invention is produced by creating a pressure differential across a web of textile fibers to slightly raise the web above the bedplate in a needleloom during the needling operation. The pressure differential is creature by air pressure introduced beneath the web or a suction created above the web, or a combination of both. By needling the web in selected positions, and varying the air supply or vacuum as necessary, a desired high-low or corduroy texture in the resulting product can be effected.

Turning now to the drawings, FIGS. 1 and 4 show one example ofa textile product formed in accordance with this invention. It includes a web 10 of randomly interwoven textile fibers ll needled through a carrier or substrate scrim 12 at various positions 13 thereof, producing tufts l4 beneath scrim 12. The resulting has a high-low effect due to the displacement of the fibers achieved by moving the web 10 towards the needles of the needleloom as they descend to needle the web. Scrim 12 may be employed depending on the end uses of the resulting textured textile product; however the invention may be practiced without the scrim. As

shown in FIGS. 1 and 4, scrim 12 is an interwoven material. However, scrim 12 can be formed of any other suitable material in any suitable manner.

Toproduce the textured textile product of FIGS. 1 and 4, apparatus of FIGS. 2 and 3 may be used in accordance with the invention. The apparatus includes needleloom 20 comprised of a needle board 21, a stripper plate 22, and a bedplate 23. In the specific embodiment shown needle board 21 has a plurality of needles 24 arranged uniformly in parallel or straight rows separated by a predetermined spacing. Stripper plate 22 is provided with a plurality of holes 25 which accept needles 24 of needle board 21 when the needle board is lowered during the needling operation. In a like manner, bed plate 23 is provided with a plurality of holes 26 which accept needles 24 during the needling operation. Such a needleloom is conventional and well known and needs no further detailed description.

In accordance with one embodiment of the present invention, air supply means (not shown) is disposed beneath bed plate 23 to supply a stream of air through line 31 to web through holes in bed plate 23. These holes may be holes 26 which accept needles 24 during the needling operation, orcan be a plurality of further holes (not shown) which are separately supplied for this purpose. Although only one air conduit 31 in FIG. 2 has been schematically depicted, it should be apparent that several such means would be employed to raise web 10 above bed plate 23. It should also be apparent that a manifold or other air direction and accumulation means could be placed under bed plate 23 to direct air from a single air source through all holes in bed plate 23, or only a portion thereof as desired.

In another embodiment of the invention, air conduit 31 can be supplemented or replaced by air conduit 32 supplied from the same air source (not shown). Con duit 32 supplies air to the web material just before bed plate 23, thereby raising the web prior to the needling operation. Air is directed to the web by baffle 27, desending at an incline from bed plate 23 as shown.

In another embodiment of the invention, the air stream through conduits 31, 32 can be supplemented or replaced with a vacuum or suction producing means generally designated 33. A vacuum head 34 is disposed in the needleloom above bed plate 23 at the entrance of the loom or otherwise positioned to lift the web 10 just prior to the needling operation.

In operation air supply means 31, 32 or vacuum means 33 may be operated on an intermittent basis to create further decorative effects in the finished product, such as a more pronouneedhigh-low effect or a rounded pattern. Also a combination of air supply means 31, 32 and vacuum means 33 may be employed to produce a textured textile of desired surface effect or configuration.

To construct the textured textile product of the invention, prior to entering the needleloom, a web 10 of randomly interwoven textile fibers is formed in a conventional card and lapper mechanism (not shown). Web 10 is then drafted through draft rollers 35 to develop an even fiber arrangement and passed onto apron 36 as shown in FIG. 2. Depending on the end uses of the textile product, a scrim 12 may be added to web 10 just prior to introduction into needleloom 20. Upon entrance into needleloom 20, web 10 is lifted by an appropriate pressure differential created across the web as described above. In the raised state, web 10 passes between stripper plate 22 and bed plate 23 of needleloom as the needles are being lowered. Needle board 21 is then further lowered, extending needles 24 through stripper plate 22 and uniformly pushing or punching the fibers 11 together. When a scrim 12 is employed, the needled portion of web 10 is pushed through scrim 12, forming tufts l4. Needle board 21 is then raised, thereby disengaging needles 24 from the web and returning them through stripper plate 22, where any material adhering to the needles 24 is removed. The needled textile product is then withdrawn from needleloom 20 and wound onto a roll 37.

In a further embodiment of the invention, a conventional oscillating wave line mechanical attachment (not shown) can be placed against the scrim to also form a wave line effect in the texture. This wave line attachment is commonly used in the art to provide carpet designs and can be employed either before and/or after the needling operation. In the alternative, a programmed oscillation utilizing a gear arrangement, or cam device, can be substituted for the wave line device.

The amount of air pressure or vacuum employed in the invention depends on several factors, including web thickness, construction of the specific fibers in the web, density of the web, and whether a scrim is included. Therefore, widely varying air pressures or vacuum values will depend on the materials used to practice the invention. However, it has been determined that a 5 to 10 pound air pressure is sufficient for a 10 to 12 ounce web, in a 15 denier size fiber.

After the product has been developed, it can be stabilized further, when required, by a latex or rubberized backing material, heating and consequent melting of synthetic textile'fibers (if employed), and use of various other materials, depending on the tgequirements for end use. Other textures can be effected in the textile product by subsequent needling, sewing, embossing, or the like.

It should therefore be obvious to one skilled in the art that the invention may be embodied in other specific forms without the departing from the spirit of essential characteristics thereof. The scope of the invention is indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and intent of the claims will, therefore, not depart from the true spirit and scope of the invention.

What is claimed as new and desired to be secured by a United States letters Patent is:

1. Method of producing a textured textile product from a continuous web of interwoven textile fibers being passed through a needleloom including the steps of:

creating a pressure differential across the web as it passes into the needleloom to move and suspend the web in said needleloom, and

needling said web together in specific areas with spaced needles in said needleloom to produce a predetermined high-low pattern.

2. Method of claim 1 wherein the web is conveyed along a path over a bed plate included in the needleloom, and wherein the pressure differential is created at a location adjacent to but up said path from said bed plate.

3. Method of claim 2 wherein said pressure differential is created by directing a flowof air onto said web.

4. Method of claim 1 wherein the web is conveyed along a path over a bed plate included in the needleloom, and wherein said pressure differential is created through apertures formed in the bed plate of said needleloom. Y

5. Method of claim 4 wherein said pressure differential is created by directing a flow of air through the apertures'formed in said bed plate.

6Q'Me'thod of claim 1 wherein said pressure differential is'in'terinittentIy applied in a predetermined manner. 1

7. Method of claim 1 wherein said pressure differential is created by producing a vacuum on the web.

8. Method of claim 7 wherein said vacuum is produced above said web to raise the web.

9. Method of claim 1 wherein prior to passage to the needleloom, the web is drafted from fibers through draft rollers to develop an even fiber arrangement.

10. Method of claim 9 wherein a scrim material is placed under said web after drafting to form a backing for said web.

11. Method of claim 10 wherein said pressure differential causes the web to move in one direction and wherein said scrim is also mechanically moved in another direction to form a desired pattern.

12. Method of claim 11 wherein said scrim is mechanically moved while passing through said needleloom to form a wavy line pattern.

13. Method of claim 1 wherein said pressure differential is created simultaneous with and comingled with the needling of said web.

14. The method defined in claim 1 as applied to a textile product having a ten to twelve ounce web and wherein the fiber has a fifteen denier size, and wherein five to ten pounds air pressure is applied to the web to suspend the web in the needle loom prior to or simultaneously with the needling operation in order to produce said predetermined high-low pattern.

15. In forming a textile product, a method of interlacing fibers to produce a high-low surface effect in the fibers, the steps including:

passing a web of fibers through a needleloom, raising the web in one direction towards the needles of the needleloom, and needling the web by moving the needles through the web in a direction opposite to said first direction, and wherein said web is raised by inducing a pressure differential across the web at predetermined locations. 

1. Method of producing a textured textile product from a continuous web of interwoven textile fibers being passed through a needleloom including the steps of: creating a pressure differential across the web as it passes into the needleloom to move and suspend the web in said needleloom, and needling said web together in specific areas with spaced needles in said needleloom to produce a predetermined high-low pattern.
 2. Method of claim 1 wherein the web is conveyed along a path over a bed plate included in the needleloom, and wherein the pressure differential is created at a location adjacent to but up said path from said bed plate.
 3. Method of claim 2 wherein said pressure differential is created by directing a flow of air onto said web.
 4. Method of claim 1 wherein the web is conveyed along a path over a bed plate included in the needleloom, and wherein said pressure differential is created through apertures formed in the bed plate of said needleloom.
 5. Method of claim 4 wherein said pressure differential is created by directing a flow of air through the apertures formed in said bed plate.
 6. Method of claim 1 wherein said pressure differential is intermittently applied in a predetermined manner.
 7. Method of claim 1 wherein said pressure differential is created by producing a vacuum on the web.
 8. Method of claim 7 wherein said vacuum is produced above said web to raise the web.
 9. Method of claim 1 wherein prior to passage to the needleloom, the web is drafted from fibers through draft rollers to develop an even fiber arrangement.
 10. Method of claim 9 wherein a scrim material is placed under said web after drafting to form a backing for said web.
 11. Method of claim 10 wherein said pressure differential causes the web to move in one direction and wherein said scrim is also mechanically moved in another direction to form a desired pattern.
 12. Method of claim 11 wherein said scrim is mechanically moved while passing through said needleloom to form a wavy line pattern.
 13. Method of claim 1 wherein said pressure differential is created simultaneous with and comingled with the needling of said web.
 14. The method defined in claim 1 as applied to a textile product having a ten to twelve ounce web and wherein the fiber has a fifteen denier size, and wherein five to ten pounds air pressure is applied to the web to suspend the web in the needle loom prior to or simultaneously with the needling operation in order to produce said predetermined high-low pattern.
 15. In forming a textile product, a method of interlacing fibers to produce a high-low surface effect in the fibers, the steps including: passing a web of fibers through a needleloom, raising the web in one direction towards the needles of the needleloom, and needling the web by moving the needles through the web in a direction opposite to said first direction, and wherein said web is raised by inducing a pressure differential across the web at predetermined locations. 